Technology presses printing industry ahead: automation streamlines process, tracks results.

In today's rapidly changing business world, commercial printers must constantly be a step ahead of their competition. Any edge they can gain over another printer puts them closer to finalizing a sale, and technology helps provide that edge.

A keen awareness of their competitors and larger industry trends allows printers to see beyond their current technology and plan for tomorrow. A successful commercial printer will recognize the importance of streamlining its operation through the use of state-of-the-art presses, automation and computer-to-plate technology.

Press technology has changed dramatically over the past several years. Fortunately, press manufacturers have put the demands of printers at the forefront of their designs, recognizing the need for increased productivity and efficiency.

In order to accommodate faster make-readies, press speeds and higher quality, commercial printers are acquiring these state-of-the-art presses. Although this equipment helps differentiate them in the marketplace, it comes with a hefty price tag.

For example, Heidelberg six-color-plus-coater, sheet-fed, off-set printing press is a multi-million dollar capital investment. The 40-inch press prints 15,000 sheets an hour and features a unique air-cushion transfer system for mark-free sheet travel.

This allows press operators to make ready-color and register then go right into production without any delays -- even on the heaviest ink coverage jobs. The sheets float on air and nothing touches during production, ensuring consistent high quality through every run. This press can cut pre-production time by as much as 50 percent, which allows for faster service at more competitive rates.

* Automated Shop Way of the Future

The industry as a whole is moving towards a more automated shop with a wide system of controls, checks and balances. This system would be able to handle everything from remote estimates and order entry requests, through the estimating, planning, production and finally the shipping of the product.

A completely automated system is not only beneficial to the printer, in terms of greater efficiency, but also to the client. Costs can be tracked from start to finish and be applied not only to the current job being produced, but also to a future, similar job.

Customized efficiency reports can also be generated. This leap in technology insures high quality and is cost-effective and feasible.

Automation is key and computers are the answer. Press one button and your plates are on and in register, the blankets are washed and the ink fountains are set, all in a matter of minutes.

* This process might take an hour with a non-automated press. Automation continues during the printing process to monitor heat and color consistency.

"Hickies," or spots on the printed paper, are eliminated with a dampening technology that wipes the printing plate clean with every revolution.

Due to tougher competition, customer needs and increased productivity demands, what was once a three- to four-day production cycle has now turned into a one- to two-day production cycle. Computer-to-plate, also known as CTP, has allowed for this reduction in production. This technology is fast becoming the printing standard for both quality and consistency. Because of this, nowhere has technology in printing changed more rapidly than in the area of the pre-press. The elimination of film allows for much faster proof generation.

Also, the high resolution of the image on a digital plate vs. conventional plates reduces make-ready time and increases print sharpness and quality on the press. Once proofs are approved, plates can be generated in about 20 minutes.

The correction cycle of a digital workflow also allows for a much faster, less expensive correction cycle. Plate remakes are greatly reduced due to the elimination of dust-related imperfections.

* Team Effort

Due to numerous technological advances, operators no longer perform their task without regard to what was done prior in the steps of production. The industry is leaning towards a more comprehensive, shop-wide approach to the production process.

Those responsible for each step of the printing process work together as a cohesive team, thereby reducing production time and assuring quality standards. A streamlined printer will feature a computer tracking system tracing every print project from beginning to end, whether it's a simple one-color job or a sophisticated six-color die-cut assignment.

In addition, the completion of the prestigious ISO 9002 certification also assures quality standards in management and production systems. ISO efficiency also means big savings resulting in a higher quality product, faster turn-around on jobs and competitive prices.

Technology will continue to drive the future of the printing industry, as clients demand better and faster service. Today's printer must stay informed of the changing technology and be prepared to make the capital investments needed to remain competitive.

As in any business, a printer is only as good as his or her last print job. So, it better be done right, and done fast. And technology can make all the difference.

Solarsh is vice president of Carlsbad-based CPS Printing.